How to Cut Your Asphalt Driveway

Before you think about making that first cut, grab your protective gear. Asphalt cutting kicks up sharp debris, thick dust, and a ridiculous amount of noise—none of which you want to deal with unprotected. Start with safety glasses or a face shield to keep flying chunks out of your eyes. A dust mask or respirator keeps your lungs from inhaling the fine particles that linger in the air. And as for the noise, wear earplugs. Your protective gear should also include work gloves, steel-toed boots, and durable clothing (long sleeves and pants) to shield your hands, feet, and skin during your DIY project.

Not all saws and blades are up for the challenge of asphalt. If you grab just any old circular saw with a standard blade, you’ll waste time, wreck your equipment, and struggle through the job.

Choose a circular saw with a diamond blade. It’s your best bet for smaller projects. Just make sure the blade is specifically rated for asphalt—the material can be tough and abrasive, and a diamond blade is both sharp and powerful enough to handle it.

There are two blade types to consider. Dry-cutting blades work without water but generate a ridiculous amount of dust and can overheat fast. Alternatively, wet-cutting blades use water to cool the blade and control dust, making them the better option for most jobs.

If you’re cutting deep or tackling a bigger project, you may skip the circular saw altogether and go for a cut-off saw (also called a concrete saw). These powerful tools are built for serious cutting—leave these projects to the professionals—and often include a water feed system to keep the dust down and the blades running smoothly.

Keeping your asphalt clean and free of debris makes all the difference when cutting into your driveway. Grab a stiff-bristled broom and sweep thoroughly—every rock, leaf, and bit of loose debris needs to go. If you don’t, those stray materials can turn into dangerous projectiles or jam up your saw blade, slowing you down and putting you at risk. Plus, a cluttered surface can throw off your cutting lines and leave you with an uneven cut. 

First, measure the area carefully, and double-check to ensure your cut is exactly where you want it. Once you’re confident in your measurements, use chalk to mark the lines. For a straight edge, use a metal ruler or level to keep everything aligned. For more detailed work, like curves or intricate shapes, consider creating a template out of cardboard or plywood. Once your lines are marked, score them lightly with a chisel (or screwdriver) and hammer. This groove gives the saw blade a clear path to follow and keeps it from going off track.

Figure out the thickness of the asphalt. Start by checking for any exposed edges—like where the asphalt meets a curb or a previous cut—and measure with a ruler. Residential driveways typically range from two to four inches, but this can vary depending on things like soil condition, traffic load, and installation quality.

Once you know the asphalt thickness, adjust your saw blade. You’ll want the blade set slightly deeper than the measured asphalt depth to ensure a clean cut all the way through. Add about a quarter to half an inch beyond the asphalt thickness. Most saws have an adjustable depth setting, so check your saw’s manual for specific instructions on adjusting it.

If you’re unsure, a quick test cut in a less visible spot can help you confirm the depth.

Position the blade just outside your marked line and let the saw reach full speed before gently lowering it onto the asphalt. Don’t rush this. With consistent pressure, ease it into the surface so you avoid forcing the blade or veering off course. Once you’ve made the cut, don’t pull the saw out just yet. Allow the blade to come to a complete stop before you lift it. Finally, inspect your cut to make sure it’s clean and accurate. If you have more cuts, repeat the process.

Use a shovel or pry bar to lift and remove the cut sections. Insert it into the cut line and use leverage to break the asphalt free from the base below. If the asphalt is thick or tightly bound, a sledgehammer can help. Strike along the cut lines or in the middle of larger sections to break them into smaller, manageable pieces—just be careful not to damage the surrounding area.

For the smaller pieces, you can lift them by hand but always wear gloves to protect your hands from sharp edges. If you’re dealing with heavier sections, use a shovel to lift them—or get some help if it’s too much to handle for one person. For particularly large chunks, don’t hesitate to break them down further with the sledgehammer before lifting them out. Once all the pieces are removed, your job is done.